Self-insulating covering element



Aug. 6, 1968 A. A. BLAU ETAL SELF- INSULATING COVERING ELEMENT Filed July 11, 1966 INVENTURS 14177794? A. 5.4 140 A 0 4. sauna/mm 0324a 6N4; 59559, 6528 fam 1v United States Patent 3,395,508 SELF-INSULATING COVERING ELEMENT Arthur A. Blau, Merrick, and Leo L. Schlackman, Huntington, N.Y., assignors to Extrudyne, Inc., Copiague, N.Y., a corporation of New York Filed July 11, 1966, Ser. No. 564,296 5 Claims. (Cl. 52-530) ABSTRACT OF THE DISCLOSURE A double-walled insulating element which is selfinsulating in nature in that an air pocket is defined between the individual walls thereof. The walls and the pocket define an excellent insulating system which may be utilized as siding, the slats of an awning, and indeed in any other environment. A preferred embodiment of the invention comprises two such double-walled elements including one wall of which is coextensive with both such element such that in reality the two elements are of unitary construction.

This invention relates to improvements in what may be broadly designated as the construction field, and more particularly relates to a novel double-walled, self-insulating element which may be utilized in awning construction, siding construction, and indeed in any other environment where it is desirable to cover a specified area with a thermally insulating material.

In the construction of awnings, it is customary to provide a canopy-like structure which extends from a wall above a window, door, patio or carport which is to be protected from environmental elements such as sun and rain. Early awning construction favored canvas or a similar cloth-like material to form the outstanding canopy, while todays awning builders lean toward thicker materials such as wood, or metal, which, in addition to providing a more rigid structure, more importantly provide better insulating characteristics which thermally protect the window or other areas from the heat of the suns rays. Where wood is being utilized, it is further necessary to secure to the exterior surface thereof a metallic skin to improve appearance while at the same time protect the wood from rotting.

In the area of siding construction, manufacturers are similarly faced with problems of providing rigid, eye pleasing, covering surfaces while at the same time thermally insulating the interior of a structure from the heat of summer as well as the cold of winter. To provide siding with both rigidity and proper insulating characteristics, manufacturers have generally utilized a metallic exterior surface, backed by insulating material such as wood. An example of such construction may be seen in United States Patent 3,093,935 issued June 18, 1963, to H. S. Dunn.

In contradistinction to the prior art outlined above, the instant invention provides a basic double-walled covering element which is self-insulating in nature in the sense that the air pocket defined by the individual walls thereof, plus the walls themselves, provide an excellent insulating system which eliminates the necessity of providing backing or additional insulation on the typical single wall construction elements of the prior art. It will be appreciated that the basic double-walled, self-insulating covering element of the instant invention may be utilized as siding, as the slats of an awning, and indeed in any other environment where it is desirable to provide a rigid covering having excellent thermal insulating characteristics.

In one particularly advantageous embodiment of the instant invention, the basic double-walled element is defined by first and second planar walls spaced apart by upstanding end walls which extend along the opposite edges of the planar walls to define an interior cavity which extends along the length of the element. Extending from the oppositely disposed end walls are male and female connecting means, respectively, which may be mated with the cooperating male and female connecting means of a similar double-walled element positioned adjacent thereto. Preferably each double walled element includes an outstanding flap portion which overlaps the planar Wall of an adjacent element when such elements are joined in the above manner. To further maintain the planar walls of the element in spaced apart relationship there is provided at least one rib intermediate the oppositely disposed end walls and parallel thereto, which rib divides the interior cavity into a plurality of longitudinally extending air retaining channels which further enhances the insulating characteristics of the overall element. It will be appreciated that, if desired, the longitudinally extending channels may be filled with other insulating material.

In its preferred embodiment the above described double-walled element is constructed of polyvinylchloride or other plastic material as a unitary member and as such may be conveniently manufactured by utilizing a single extrusion process.

A second embodiment of the instant invention comprises two of the double-walled elements described immediately above. However, one wall of the member is coextensive with both such elements whereby the element is, in reality, of unitary construction. As was the case for the single element, opposite end walls of the thus defined double element section include oppositely extending male and female portions for joining the section to sections positioned adjacent thereto while one of such opposite end walls includes an extending overlap portion which will lie flush on the section immediately adjacent thereto. Again the unitary construction of the plastic double element section facilitates manufacturing in a single extrusion process.

Accordingly, it is an object of the instant invention to provide a novel double-walled covering element which is self-insulating in nature in the sense that air pockets defined between the individual walls thereof, plus the walls themselves, provide an excellent insulating system.

It is another object of the instant invention to provide a novel double-walled self-insulating covering element which eliminates the necessity of providing backing or additional insulating material on the typical single wall construction elements prevalent in the prior art.

Still another object of the instant invention is to provide a novel double-walled self-insulating covering element which is useful in the construction of awnings, siding, and/or in any other environment in which it is desirable to cover a specified area with a thermally insulating material.

Yet another object of the instant invention is to provide a novel double-walled self-insulating covering element which is rigid in nature.

Still another object of the instant invention is to provide a novel double-walled self-insulating covering element which is, preferably, constructed of polyvinylchloride or other plastic material and which is of unitary construction, whereby it may be easily manufactured in a single extrusion process.

Still another object of the instant invention is to provide a novel double-walled self-insulating covering element which includes oppositely disposed male and female type connecting means, whereby a plurality of such elements may be interconnected to cover a large are-a.

Yet another object of the instant invention is to provide a novel double-walled self-insulating covering element which includes an outstanding overlap section which provides for a smooth, water-tight transition between adjacent element-s when they are interconnected.

Other objects and a fuller understanding of the instant invention may be had by referring to the following description and drawings, in which:

FIGURE 1 is a perspective view of a typical awning;

FIGURE 2 is a perspective view of the basic doublewalled self-insulating covering element of the inst-ant invention;

FIGURE 3 is an end view of a plurality of the basic double-walled element of FIGURE 2, shown in assembled relationship; and

FIGURE 4 is a perspective view of an embodiment of the instant invention which utilizes essentially two of the double-walled elements of FIGURE 2.

Turning to FIGURE 1, there is shown a walled surface in which is a window 12 to be shielded by an awning structure, generally designated 14. Typically, such awning structures include a frame member 16 which supports a plurality of slats or members 18 designed to shade the window 12. As will be further explained, the instant invention is directed to a novel covering element which may be utilized as the slats 18 in the awning structure 14, but it is to be understood, and will be further explained, that the instant invention is useful to form exterior siding, and in fact is further useful in any environment where it is de sired to cover a specified area with a thermally insulating material.

As shown in FIGURE 2, the basic covering element 20 of the instant invention is of double-walled construction, including first and second planar walls 22 and 24, respectively, which are spaced apart by first and second end walls 26 and 28, respectively, disposed along opposite edges of the planar walls 22 and 24 to define an interior cavity 30 extending along the length 32 of the covering element 20.

Spaced intermediate of the end walls 26 and 28 are a plurality of internal ribs 34 which serve to maintain the spacing between planar walls 22 and 24, and further su-bdivide the interior cavity 30 into longitudinally extending channels 36, 38 and 40. The air-retaining channels de fined by the end walls and ribs form an intermediate insulating medium such that for insulating purposes, the element 20 may be thought of as having 3 distinct layers of insulating material, that is, the two planar walls 22 and 24 and the air pockets sandwiched therebetween.

Extending from the oppositely disposed end walls 26 and 28 are male and female connecting members 42 and 44, respectively, which, as will be further explained, permit a plurality of the basic covering elements 20 to be interconnected to cover a larger area than defined by any one such element.

Extending from end wall 26 is an overlap flap 46 which overlies and is flush with the first planar wall 22 of an adjacent element 20 when two such elements are joined in a manner to be described below.

Preferably, the insulating element 20 is constructed of polyvinylchloride, or other similar plastic material, and is of one-piece construction whereby the entire element 20 can be manufactured in a single extrustion operation,

It will be appreciated that because of the rib supported rectangular cross-section, the element 20 is substantially rigid in nature and because of the three layer mode of insulation described above has excellent insulating characteristics.

Turning to FIGURE 3, there is shown a manner in which a plurality of elements 20 may be interconnected and overlapped to cover an area larger than any one of the individual elements. Specifically, each of the covering elements 20 is secured by suitable means to a support indicated at 48 which could be the external wall of a house, building, etc., or in fact a frame member 16 of an awning such as that shown in FIGURE 1. Alternatively, the support member 48 could 'be part of any surface which must be covered by material which will be rigid in nature, have excellent insulating characteristics, while at the same time provide a pleasing external appearance. Each element is arranged such that the forwardly extending male type connecting member 42 is received by the inturned female connecting member 44 of the element above, while the overlap fiap 46 of each element lies fius-h on the upper planar wall 22 0f the adjacent element 20.

Turning to FIGURE 4, there is shown an alternative embodiment of the instant invention wherein a basic covering element 50 is seen to include what appears to be two elements 20' of the type shown and described with respect to FIGURE 2. Actually the composite element 50, now designated a section, is of unitary construction and comprises a first intermediate planar wall 52 with second and third planar walls 54 and 56, respectively, disposed on opposite sides of the central planar wall 52 and spaced therefrom. First and second end walls 58 and 60 space third planar wall 56 from first planar wall 52, while third and fourth end walls 62 and 64 space second planar wall 54 from first planar wall 52 to define longitudinally extending cavities 66 and 68 along the length of the section 50.

A plurality of ribs 70 are positioned in each of the cavities 66 and 68 to divide such cavities into a plurality of longitudinally extending channels 72. It will be seen that an intermediate portion 74 of the first planar wall 52 is coextensive with both interior cavities 66 and 68 whereby the resultant structure can in fact be of unitary construction and is materially more rigid than if the end walls 60 and 62 were in the same plane.

First and fourth end walls 58 and 64, respectively, have projecting mateable male and female connecting portions 76 and 78, respectively, whereby a plurality of covering sections 50 may be connected in a similar manner as that shown for the elements 20 in FIGURE 3. Similarly, the end wall 58 includes an outstanding overlap flap 80 which overlies the second planar wall 54 of an adjacent covering section 50 when adjacent elements are interconnected to cover a large area.

As was the case for the elements 20 of FIGURE 2, covering section 50 of FIGURE 4 is preferably formed of polyvinylchloride, or other substantially rigid plastic material, and because of its unitary construction can be easily manufactured by a single extrusion process.

It will be appreciated that the covering section 50 of FIGURE 4 has the advantageous insulating characteristics of the element 20 of FIGURE 2 in that the three layer sandwich of planar wall, air pocket, and planar wall, is achieved along its entire width.

Thus there has been described a basic double-walled self-insulating covering element and an alternative embodiment thereof, which, because of its three layer sandwich construction of material, air, and material, achieves outstanding insulating characteristics without the necessity of providing a separate backing of insulating material which is common in the prior art.

It will be appreciated that the basic covering element of the instant invention has a multitude of uses, only two of which have been specifically identified as slats in awning construction, and siding for exterior walls.

Although there has been described a preferred embodi ment of this novel invention, many variations and modifications will now be apparent to those skilled in the art. Therefore, this invention is to be limited, not by the specific disclosure herein, but only by the appending claims.

We claim:

1. A self-insulating section comprising:

a first planar wall of substantially rigid material;

a second planar wall of substantially rigid material disposed on a first side of said first planar wall and spaced therefrom to form a self-insulating space therebetween; and

a third planar wall of substantially rigid materil disposed on a second side of said first planar wall and spaced therefrom to form a self-insulating space therebetween;

wherein said first and second Walls and said first and third planar walls are joined by first and second, and third and fourth end walls, respectively, which extend along opposite edges of said second and third planar walls, respectively, to define a pair of interior cavities extending along the length of said section.

2. The self-insulating section of claim 1, wherein said first and fourth end walls have mateable connecting means extending therefrom for removably connecting said selfinsulating sections to other self-insulating sections of similar construction.

3. The self-insulating section of claim 1, wherein said second and third planar walls overlap one another in different planes such that a portion of said first wall is coextensive with each of said cavities.

4. The self-insulating section of claim 1, and further including at least one rigid rib positioned in each of said cavities intermediate said first and second and third and fourth end walls, respectively, and substantially parallel thereto to further maintain said second and third planar walls in spaced apart relationship with respect to said first planar wall, said ribs dividing said interior cavities into a plurality of channels extending along the length of said section.

5. The self-insulating section of claim 4, wherein said first and second, and third and fourth end walls and the ribs respectively positioned intermediate thereof are integrally joined with said first planar wall and the associated one of said second and third planar walls, and are constructed of the same material as said planar Walls whereby said section is thereby necessarily of unitary construction and can be easily manufactured in a single extrusion step.

References Cited UNITED STATES PATENTS 1,341,071 5/1920 Requa 52-609 3,100,556 8/1963 De Ridder 52588 3,301,147 1/1967 Clayton 52-588 FOREIGN PATENTS 401,422 5/ 1966 Switzerland.

REINALDO P. MACHADO, Primary Examiner. 

